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supercharged 5.0 true fire 98 explorer sport

hi everyone, my name is tim . i live in selkirk, manitoba, canada and as if this date that i am posting this, i am 36 years old.

i bought my sport in jan 05 from a local ford dealer. it had 111,000KM's on it. this is the second sport i have owned. it was sitting on the lot for about 8 months before i came along. i am the third owner (i was able to track down the person that traded it in, and they got it from a friend, who bought it new in 98).

i started to do a few things to it after i first got it, then i found this site, and all hell broke lose! i've never been satisfied with something the everyone else has, so i started to tinker with it even more.

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mods include

interior

installed factory tilt, cruise, overhead console, auto dimming mirror, full length console, with a message center (it didn't have these from factory).

white face with blue flames indigo gauge covers (they light up blue)
blue l.e.d. everything
white l.e.d. interior lights
Kenwood DDX392 Touch Screen Head Unit
alpine 4 channel amp (all four speakers)
boston acoustic front and rear speakers
alpine mono amp (for sub)
2 12 inch jl audio subs
rockford fosgate cap
passenger side one touch window down mod.
custom transfer case shifter
tripple a pillar gauge pod, housing autometer boost, Innovate LC-1 wideband, and oil pressure gauge
12v power inverter with 120v plug in a 2 usb plugs built into the center console

exterior

BMW E46 projectors, mounted into stock housings using clear lens
6000K HID head lights
angel eye "driving" lights, with 8000k h.i.d.'s
clear parking/corner lights
billet grill (powder coated by Turdle)
blacked out ford emblems
custom front steel 95-98 bumper, with 4 inch round tubes welded in for driving lights
shaved radio antenna
shaved roof rack
black euro tall lights
l.e.d. license plate lights
smoked out 3rd break light
lund rear tailgate spoiler/wing (formally from the truck "blackjack" owned by EF member Spas)
hand made roll pan (made from 3 1/2 rear bumpers, with 1/4 inch diamond plate on the top, and it is removable)
aluminum T/A differential griddle/cover (powder coated by Turdle)
Motegi Mr107 20' rims
goodyear wrangler hp p245/50 r20
1 1/4 wheel spacer in the rear, 3/8 in front
and most noticeable, black with blue pearl paint, and blue true fire (ground effects are black with blue pearl as well)

Suspension

2 inch lowering blocks in the rear, reverse TT in the front (2 inch as well)
Explorer Express rear sway bar
4 door leaf springs
rancho rs9000 adjustable rear shocks
03-05 sport trac spindles with drilled and slotted rotors

performance

5L swap
347 stroker
TFS twisted wedge alum heads
comp gold 1.6 rockers
comp cams CCA-35-556-8 nitro cam
heavily modified edelbrock victor jr air gap intake (which serves as a valley pan now)
eaton m122 supercharger (metco 2.70 pulley, and ASP 8 rib 7 1/4 crank pulley) with custom made mount with bell intercooler core
8 rib serpentine belt conversion using pulleys from a 7.3 powerstroke
custom made 3 1/2 inch throttle body elbow
accufab 75mm throttle body
4 inch intake pipe
PMASS MH90 90mm Universal 3000 KG/HR MAF
amsoil cone filter
F.A.S.T. 60lb injectors
edelbrock fuel rails, trick flow specialties fuel pressure regulator with summit racing fuel pressure gauge
walbro 255lph fuel pump
1/2 inch steel braided fuel pressure line from tank to rail using 8AN fittings
torque monster headers
2 1/2 duel pipes with flowpro duel in and out 2 1/2 single muffler
accel extreme 9000 ceramic 45 degree plug wires with boot protectors
4R70W w/2600 stall with J mod
tuff stuff 200a alternator
tuning made possible with sct pro-racer package, and tuned with major help from member [MENTION=102869]Dono[/MENTION] and [MENTION=81804]4pointslow[/MENTION]
flex a lite duel 12 inch electric fans
big 3 upgrade (4 gauge wires)
meziere innercooler water pump
2 froozenboost innercooler rads

Transfer case

4406 manual shift from a 97 F150
modified stock trans cross member to accept 93 mustang 5L polyurethane tans mount
double cardan rear drive shaft

because of all the "fun" i had doing the bodywork, and some other things to my truck, i have nick named it "evil dora" or if you like, just plane "evil"!
and now the thank yous

my buddy gord leiss, who let this thing sit in his garage for 3 months while i did the body work to it. he also gave me a hand with some of the prep work, and painted it for me

kevin willson for doing the true fire http://affordableairbrushing.ca/

Joe Bukoski for letting me do the 5L/4406 swap in his garage

now people from this site, weather they knew it or not, they helped

BIG THANKS to tara a.k.a. explorersport77 for pictures of her truck. wouldn't been able to build the roll pan with out them!

ExplorerSport77's X "Hotness"

jon a.k.a. Turdle for selling me some real swanky rear shackles, as well as powder coating the diff cover and sending them up to canada. as well as much needed info on v8, and 4406 swaps as well as doing the grill and showing me how its done.

don aka dono for the help with the tuning, and wideband, as well as the supercharger

andy aka ahodges for some parts, and any help i needed for all the go faster goodies

5.0 swap - w/ 4406

jad2411 for finding me a link for my hidden antenna

ryan a.k.a. MustangP51 for doing his write up on making l.e.d.'s for interior lights, and how to make projectors

P51's HID Headlight (Projector) and Fog Conversion (PICS)

and N3ELZ cardomain page for L.E.D. switch and cruise pod mods

http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-6
http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-12
http://www.cardomain.com/ride/296394/2002-ford-ranger-regular-cab/page-23

bob a.k.a. rwenzing for showing me speedhut's sit for the gauges

Gauges, Custom Gauges, Tachometers, Speedometers, Shift Light, Pod

Buzz4x4 for his write up on blacking out ford emblems

How to Make Your Own Custom Ford Emblems

the late aldive for his write up on one touch down passengers window mod

http://www.explorerforum.com/forums/showthread.php?t=141027&highlight=touch+passengers+window+mod

BIG COUNTRY, for his write up on how to install a auto dimming mirror

http://www.explorerforum.com/forums/showthread.php?s=&threadid=84968

BIG COUNTRY, 98formulaLS1, and Ryon40 for there write ups on how to install a message center

http://www.explorerforum.com/forums/showthread.php?t=225017&highlight=BIG+COUNTRY
http://www.explorerforum.com/forums/showthread.php?t=80670&highlight=message+center
http://www.explorerforum.com/forums/showthread.php?t=245085&highlight=Ryon40

MountaineerGreen for his 4406 swap write up and "Custom" Driveshaft for a 4406 and 4" Superlift on the Cheap " (even tho its lowered

http://www.explorerforum.com/forums/showthread.php?t=166726&highlight=awd+4x4+swap
http://www.explorerforum.com/forums/showthread.php?t=185232

Simon, aka blueka for his "pickle" thread, and help anytime i picked the phone up the phone on the 5L swap

http://www.explorerforum.com/forums/showthread.php?t=271813

Jon, aka 4pointslow for any MAJOR technical advice i have needed

http://www.explorerforum.com/forums/showthread.php?t=219092

i wish i could find who did the write up on the overhead console install, but here is the link

http://www.explorer4x4.com/overhead.htm

Russ aka NICE59FORDF100 for his help on the wiring, and what to watch out for electronically.

hopefully one day, i will be able to help people on here just as much as the people that i have mentioned above!

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plus you know you have done something right when.....

your truck (as well as corkey) wins truck of the month

http://www.explorerforum.com/forums//showthread.php?t=296023

is the feature truck on the fun hump day radio show (starts roughly around the 30 min mark)

http://explorerforum.podbean.com/2011/03/23/19-vroom-zoomboom/

and you drive 26 hours ONE WAY to the carlisle all ford nationals in june 2010 and 2011, and grab second place in the s.u.v. all category!

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then in 2014 you go back to the same show you have been to 5 years in a row (nothing by most, but its one hell of a long drive) and take first!

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AWESOME!!!!
More boost, and still under the hood!
 



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got the intake back today from the machinist

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had to do a few small touch ups on it because he wasnt sure what i wanted done and didnt want to destroy something when it didnt need it. he and i were talking about a few things that we agreed on. one was that i should blend the ports in a little bit. if you look back a few pages to the link i posted, thats what the guy did to his, but what the machinist said not to bother with was smoothing the entire valley out, which was what i was going to do. i had also said its going to suck for #5 cylinder because all the heat from the water jacket is going to be transferred from it into the cylinder. nothing can be done about it, he just said that, that one cylinder might be a little lean then the others and to not freak out when i pull plugs and its white.
i also started on the mount plate as well.

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ignore the black paint. its my poor mans laydown dye. i cut the one corner a little short, it will still seal up if i blob some silicone on it. that or i might just have that corner touched up with weld. however, this part is driving me nuts

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the front part of the plate will not lay flat. the other problem with this is that the water jacket cross over humps upwards. the machinist didnt want to machine it down because it is kinda thin to start with. the only way around it is for me to shave some off the bottom of the plate. not sure if i have it just right yet, or its hanging up some other place. i will worry about that tomorrow. 5 snapped jigsaw blades, one carbide that is more then likely garbage now, and a carp load of alum splinters told me it was time to call it a night.
 






the point of no return.

today was dooms day for the case. i literally did anything i could today to avoid cutting it up to, no lie because once this was done, its useless to the entire free world!
also since the day i got it, i left the blower sealed up. figured the guy did a good job doing it, why screw up a good thing, so i never even saw what the inside looked like, let alone the rotors. looks like a bought me a mint supercharger!

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then out came the stuff you cut things with

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wanted to see how big it looked sitting on the motor. yea, still isnt small by any means.

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so i pretty much found centreline for both the blower and intake because i wanted to see how much room i would have using dono's injector rails as mock up.

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shes very tight! but it will fit. so now that i have a better idea where the injectors will land, i will start drilling the holes for them. want to do those first and avoid my grinder and cut off wheel for a little bit because.....

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that happened. they dont call em death wheels for no reason. just happy i had a full face shield on, and my head wasnt near it when it exploded on me. if you have never had one of these rip apart on you, it will wake you up and grab your attention, and like REAL fast.
so i figured this would be a good time to call it quits, grab something to eat, and a change of underwear.
 






The lower intake looks like its fitting nicely in to the valley. Your work looks awesome.

I'm glad it was cooler today, or you probably wouldn't have had that face mask on. Wow, I don't even own one of those things.
 






I wear safety glasses under the damn face shield these days. 3 years ago, I had shot a metal sliver into the white of my eyeball. Watched it bleed, with the other eye. Doc found the lens was scratched, and when he swabbed it, the swab was full of metal dust. Man that was painful.

A Welding jacket/apron, is also a good thing to wear with them devil discs. I won't pick up the grinder w/o heavy leather gloves and face protection on. As Dono said, glad you had the shield on. Scary stuff.

The progress looks pretty snazzy too. Keep at it, looking forward to the pics!
 






i am pretty religious about wearing a shield when grinding. used to wear just eye glasses but would find sometimes stuff get past them, or would feel shavings or disk particles hitting my face so i started wearing a shield. however i never wear gloves when i grind. well, i wear rubber gloves sometimes. leather gloves IMO are to loose and if by chance the grinder catches them, off comes the fingers
 












the good news.

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and a rough idea how close to the edge they are. might have to notch it a little, but i dont think that should hurt.

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the bad news

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not enough for the case to slip threw. this was something i was worried about.
BUT!

the gooder news

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that is around 3 3/4 raised up. which is the perfect height to box it for the innercooler. if i measured it right, i am still a inch shorter in height then the m112 is.
 






That's a lot of room for an intercooler!
 






That looks great. The extra volume/depth of the intake valley, gives needed space for a decent sized intercooler.
 






looks like i might be at a stand still for the moment. i need to find some alum so i can make the box the innercooler will sit in. i also have to drill the supercharger case so i can put the bolts needed to fasten it to the mount. thing is, i am not sure i trust myself to drill it because it has to be dead nuts on. if i am off in one direction or another, i drill through the case, and its game over. my buddy that is a machinist is back from holidays, but wants a few days to relax. so when he is ready i am going to have him look at it, and see if he can do it
so i figured i would look at the snout. as mentioned before, i am going to use a m112 snout on it. a m122 snout is too short and might push the blower overtop of the cam sensor. that would also defeat putting in a innercooler.

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the only other problem is the bolt patter is off by one bolt that is at the bottom. i am on the fence with this one. after all, it is a bolt on the bottom. it should still seal up. most of the tension will be on the top bolts from the belt pulling on it.

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the black dot is where the hole would have to be. but, that would also mean i would have to get around that built up with weld as well, because if i just drill a hole in it, it will leak oil from it. will have to think on this one on what to do.
looks like i am once again at a stand still

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If you place the order for the aluminum like last time, I can pick it up.

I'm with you, I think you need a machinist to drill those holes. Without the right equipment, you could be in for a world of hurt.

Coming along amazingly well.
 






thanks don. i tried calling them on friday, and i didnt get a answer, just their machine. i first have to figure out how i am going to do this. it occurred to me drilling the holes in the box i would have to make would be a problem possibly. the bit would have to be longer then 5 inches. not sure if i would trust that or not, because it would walk around in the hole, or worse, snap off. i would either have to get 2 pieces, drill them, then stack them on top of each other and get them welded, or make it the same shape as the m112 mount, and it would look like a upside down hat. but if i do it that way, i will also lose space on the inside because it would be narrower. however, i could then weld it all to the intake plate and it would never move, and the bolts would be on the outside.
this will keep me awake tonight lol.
also something was bugging me again about the height of everything so i went outside and remessured everything. if i did it right, i dont have 4 inches in height to put a cooler in it, i have 6! i wish i would have done this with the m112 years ago! the crap you think of in the shower!
i also had a brain fart. i went to my folks today (my dads birthday today, he is 75 years old and still going strong thank god!) and i drove right past your place don. i could have dropped the elbow off to you.
for those that dont know, evil is going to be a part of don's truck when his motor is done. the guy that bought my old EE m90 kit (geeze i have had a lot of superchargers on this truck!) wasnt using the intake elbow i made for it. don said he wanted to go to a larger throttlebody, but the stock elbow is only good for a 65mm throttle body. the one i made is good for 75mm. he shipped it back to me, and don will be using it.

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i think it will benefit from a coat of paint, but that will come at a cost of painting over the flames.
 


















so mother nature and it almost seems like a few other things have kicked me square in the jewels this weekend. starting with me witnessing some jerk bringing in a 99-00 sport at work to be shredded. it drives, it runs, THE FRIGGING AC STILL BLOWS COLD! and it only has around 151,000kms on it or 94,000 miles on it.....however the hoarder in me already grabbed the steering wheel (mint leather one with no shedding either) rims and tires which looked new as well. im also going to be pulling the motor out of it at some point as long as the other shift doesnt get a hold of it.
i also planned going to the last as well biggest car show they have here today, so i didnt bother getting any material to do more to the mount. because i dont have a garage, evil sits outside and i was going wash her down the night before then head to the show......until it started raining last night. wake up this morning to find out it had rained again and streets covered in puddles everywhere. no point in washing it then trying to tip toe to the show. cloudy and looking like it would rain again, i started to do some small cleaning on the valley pan, when.......power goes out...
now with nothing to do i sit and wait. then it starts to clear up and be nice and sunny out. figure ok, i havent washed the ranger in a while i will go do that. get it done, come home to power! but still pissed i missed the show thinking it was going to rain. so anyway, here are some more of todays work.

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all the hard edges are rounded off in hopes of the air to flow a little better. i was going to take the cast roughness off it, but the machinist who did the machining to it told me to leave it. i also dropped the blower case off to my buddy. he is going to see if he can drill the holes in it for me but may take a bit because he has to do it on his time.
so yea, one let down after another this weekend. cant even go to cruise night because shortly after i finished washing the ranger guess what? i rained again so now the streets are soaked once more
think i will sit back and see if it snows today.
 






I missed the show today as well. It probably wouldn't have been great because of the weather anyway.

Sounds like you scored some great parts, so that can't be a bad thing.

As for the delays you are having, I think you are moving along really fast.
 






Cheer up, your are doing amazing things right now and they take time.
I have a feeling that this new setup is going to change the whole game.
Keep up the good work.
 






i picked up the case from buddy today.

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we both are hoping it will work. he drilled and tapped them to a 1/4 inch coarse thread. i wanted to go get the alum i would need for it, but it almost seems like i have been doing things for everyone else this weekend so far, and not my own stuff. i was also looking at the sides where i cut the mounting tabs off. yea, i will be spending some quality time with a file trying to smooth out all the marks i left there. winter is also coming fast as well. looks like the sweat shop will be turning back to the gas chamber soon.
 



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well, i can sorta stomach it now.....sorta

before

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after

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i'd love to do nothing more then to send it down to @Turdle and have him powdercoat both the case, and snout, but if i do that, it will trap heat inside, and i dont want that. what i am going to do is find something like bbq paint and blend the bottom of the case in and paint the snout. then theoretically the case is done. theoretically...
 






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